[Remote] Thin-Gauge Thermoform Design Engineer

Note: The job is a remote job and is open to candidates in USA. HCLTech is looking for a highly talented and self-motivated Thin-Gauge Thermoform Design Engineer to join its team in advancing the technological world through innovation and creativity. The role focuses on designing thin-gauge thermoformed plastic components for Automotive OEM’s products, leading the design process from concept through production while ensuring manufacturability and quality standards.

Responsibilities

• This role focuses on designing thin-gauge thermoformed plastic components (e.g. lightweight trays, enclosures, packaging inserts) for Automotive OEM’s products and operations
• The engineer leads end-to-end design of thermoformed parts and tooling from concept through production, ensuring design for manufacturability in thin plastic sheet forming typically <1.5 mm thickness)
• Responsibilities include creating detailed 3D CAD models and drawings, conducting feasibility and tolerance analyses to optimize designs, and collaborating cross-functionally with manufacturing, quality, and supply chain teams to meet high-volume production and quality standards
• The engineer also supports tooling fabrication and validation with internal teams or external toolmakers to ensure that thermoforming molds and processes achieve the required performance and precision. (Notably there is flexibility for these specialized roles, even considering remote work arrangements.) This is a hands-on design position requiring technical expertise in thin-gauge thermoforming processes, creativity in problem-solving, and strong coordination skills

Skills

• A B.S. in Mechanical Engineering or a related field (e.g. Manufacturing or Industrial Design)
• 3+ years of experience designing thermoformed plastic products and tooling – particularly in thin-gauge applications (e.g. packaging or lightweight enclosures)
• Advanced skill in 3D CAD software (such as SolidWorks, CATIA, or equivalent) for complex part modeling, assembly design, and detailed drawing creation
• Strong understanding of thin-gauge thermoforming processes, including vacuum forming and pressure forming techniques
• Familiarity with thermoplastic materials commonly used in thin-gauge thermoforming (e.g. ABS, HIPS, PETG, PVC) and how they behave under heat and vacuum
• Experience in designing thermoforming molds/tooling and collaborating with toolmakers or machine shops for fabrication and validation of those tools
• Ability to optimize part designs for manufacturability, trimming, and high-volume production (DFM)
• Competence in tolerance analysis, material thickness optimization, and part feasibility studies for thin-gauge parts
• Strong attention to detail with quality control considerations for plastic part integrity and consistency
• Ability to work with cross-functional teams (design engineering, manufacturing, quality, supply chain) to refine requirements and ensure successful integration of thermoformed components into the overall system
• Excellent communication skills are essential for bridging design with production
• Prior experience in an automotive or high-volume manufacturing environment, especially involving packaging engineering or plastic component design
• Familiarity with lean/automated manufacturing processes and related plastic forming methods (e.g. heavy-gauge thermoforming or injection molding)
• Experience with CAE/FEA tools for simulating thermoformed part behavior or design optimization
• Knowledge of industry standards and testing protocols relevant to thin-gauge plastics (such as packaging standards or automotive component requirements)

Benefits

• Performance-based bonuses subject to company policies
• Medical, dental, vision, pharmacy, life, accidental death & dismemberment, and disability insurance
• Employee assistance program
• 401(k) retirement plan
• 10 days of paid time off per year (some positions are eligible for need-based leave with no designated number of leave days per year)
• 10 paid holidays per year
• Continuous opportunities for you to find your spark and grow with us
• Transparent communication with senior-level employees
• Learning and career development programs at every level
• Opportunities to experiment in different roles or even pivot industries

Company Overview

Company H1B Sponsorship